U.S. patent application number 16/248201 was filed with the patent office on 2019-05-16 for automated system and method for constructing card multipacks, and card multipack constructed using the same.
The applicant listed for this patent is Harvard Label LLC. Invention is credited to Michael Tang.
Application Number | 20190147198 16/248201 |
Document ID | / |
Family ID | 60941260 |
Filed Date | 2019-05-16 |
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United States Patent
Application |
20190147198 |
Kind Code |
A1 |
Tang; Michael |
May 16, 2019 |
AUTOMATED SYSTEM AND METHOD FOR CONSTRUCTING CARD MULTIPACKS, AND
CARD MULTIPACK CONSTRUCTED USING THE SAME
Abstract
Automated systems, methods for constructing card multipacks, and
a card multipack constructing using the same are provided. An
automated system for constructing card multipacks includes: a
movable conveyor including a plurality of tooling plates, each
configured to receive a height adjusting member; a first carrier
placing station configured to place a first carrier portion of a
carrier on a tooling plate of the plurality of tooling plates; a
first card placing station configured to place a first stored value
card on the first carrier portion; a first data capture station
configured to read a first card bar code of the first stored value
card in-line in the automated system; and a software system adapted
to verify the first card bar code with a data file.
Inventors: |
Tang; Michael; (Monterey
Park, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Harvard Label LLC |
Wilmington |
DE |
US |
|
|
Family ID: |
60941260 |
Appl. No.: |
16/248201 |
Filed: |
January 15, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15636172 |
Jun 28, 2017 |
10248816 |
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16248201 |
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62357859 |
Jul 1, 2016 |
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Current U.S.
Class: |
235/494 ;
235/462.41 |
Current CPC
Class: |
B65B 7/2807 20130101;
G06K 1/121 20130101; B65B 51/32 20130101; G06K 7/1439 20130101;
B65B 63/005 20130101; B65B 7/2878 20130101; B65B 61/025 20130101;
B65B 35/18 20130101; B65B 5/105 20130101; B65B 13/185 20130101 |
International
Class: |
G06K 1/12 20060101
G06K001/12; G06K 7/14 20060101 G06K007/14; B65B 13/18 20060101
B65B013/18; B65B 7/28 20060101 B65B007/28; B65B 35/18 20060101
B65B035/18; B65B 63/00 20060101 B65B063/00; B65B 61/02 20060101
B65B061/02; B65B 51/32 20060101 B65B051/32; B65B 5/10 20060101
B65B005/10 |
Claims
1-20. (canceled)
21. An automated system for constructing card multipacks, the
automated system comprising: a movable conveyor comprising a
plurality of tooling plates; a first carrier placing station
configured to place a first carrier portion of a carrier on a
tooling plate of the plurality of tooling plates; a first card
placing station configured to place a first stored value card on
the first carrier portion; a first data capture station configured
to read a first card bar code of the first stored value card and
create a data file in-line in the automated system, the data file
comprising an association between at least the first card bar code
and a carrier bar code; and a software system adapted to verify the
first card bar code with the data file.
22. The automated system of claim 21, wherein the first data
capture station comprises a first camera configured to create a
first image of the first card bar code, and the software system is
adapted to verify the first card bar code using the first
image.
23. The automated system of claim 22, further comprising a second
carrier placing station between the first data capture station and
a sealing station configured to seal the carrier, the second
carrier placing station configured to place a second carrier
portion of the carrier on the first stored value card subsequent to
the first data capture station reading the first card bar code,
wherein the second carrier portion comprises the carrier bar
code.
24. The automated system of claim 23, further comprising a second
data capture station between the second carrier placing station and
the sealing station, the second data capture station comprising a
second camera configured to create a second image of the carrier
bar code, and the software system is adapted to verify the carrier
bar code using the second image.
25. The automated system of claim 24, wherein the first card bar
code comprises a parent card bar code, and the data file further
comprises an association between the parent card bar code and the
carrier bar code.
26. The automated system of claim 25, wherein the first data
capture station is configured to read the first card bar code
between the first card placing station and the sealing station, and
the second data capture station is configured to read the carrier
bar code between the second carrier placing station and the sealing
station
27. The automated system of claim 26, wherein the software system
is adapted to verify the first card bar code and the carrier bar
code in-line in the automated system and provide an output before
the sealing station seals the carrier.
28. The automated system of claim 27, wherein the output comprises
a warning that the first card bar code or the carrier bar code was
not verified by the software system.
29. The automated system of claim 28, wherein the sealing station
does not seal the carrier when an output comprising a warning is
provided.
30. The automated system of claim 27, wherein after verifying the
carrier bar code, the first card bar code comprising the parent
card bar code, or a combination thereof, each stored value card
within the carrier is activated by the parent card bar code after
the sealing station seals the carrier.
31. The automated system of claim 30, wherein the parent card bar
code is readable through a window of the first carrier portion or
the second carrier portion after the carrier has been sealed.
32. A method for constructing card multipacks using an automated
system, the method comprising: placing a first carrier portion of a
carrier on a conveyor of the automated system using a first carrier
placing station of the automated system, the conveyor including a
plurality of tooling plates; placing a first stored value card on
the first carrier portion using a first card placing station of the
automated system; reading a first card bar code of the first stored
value card in-line using a first data capture station of the
automated system; and verifying the first card bar code with a data
file using a software system of the automated system, the data file
comprising an association between at least the first card bar code
and a carrier bar code.
33. The method of claim 32, wherein the first card bar code
comprises a parent card bar code, and the data file further
comprises an association between the parent card bar code and the
carrier bar code.
34. The method of claim 33, wherein reading the first card bar code
comprises creating a first image of the first card bar code using a
first camera, and the software system is adapted to verify the
first card bar code using the first image.
35. The method of claim 34, further comprising: placing a second
carrier portion of the carrier on the first stored value card using
a second carrier placing station of the automated system subsequent
to reading the first card bar code, the second carrier portion
comprising the carrier bar code; reading the carrier bar code of
the second carrier portion in-line using a second data capture
station of the automated system, wherein reading the carrier bar
code comprises creating a second image of the carrier bar code
using a second camera; and verifying the carrier bar code using the
second image.
36. The method of claim 35, further comprising sealing the carrier
in-line using the automated system after the carrier bar code, the
first card bar code comprising the parent card bar code, or a
combination thereof is verified.
37. The method of claim 36, further comprising activating each
stored value card within the carrier using the parent card bar
code, after the carrier is sealed.
38. The method of claim 35, further comprising providing an output
before sealing the carrier in-line using the automated system.
39. The method of claim 38, wherein the output comprises a warning
that the first card bar code or the carrier bar code was not
verified by the software system.
40. The method of claim 39, further comprising not sealing the
carrier in-line using the automated system when an output
comprising a warning is provided.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 62/357,859, filed on Jul. 1, 2016, the
entire content of which is hereby incorporated by reference.
FIELD
[0002] Aspects of embodiments of the present invention relate to
card multipacks, and more particularly, to automated systems and
methods for constructing card multipacks, and a card multipack
constructed using the same.
BACKGROUND
[0003] Stored value cards distributed, for example, by financial
institutions, telephone companies, or other providers of goods and
services are typically forwarded to retail merchants for sale to
individual purchasers. These stored value cards allow the holder
prepaid access to existing phone networks for making phone calls,
for example, eliminating the need to carry cash on hand.
Additionally, stored value cards may be used to provide
authorization for the rental or purchase of goods and services, or
may be used as a gift certificate granting the holder credit for
various goods and services.
[0004] Stored value cards are typically purchased by merchants
similar to any other good, and displayed for sale in the merchants'
stores. In order to reduce their exposure to the loss of the
valuable cards through theft or fraud, it is typically the practice
for merchants to sell non-activated, or "zero balance" stored value
cards which have no intrinsic value until they are activated by the
merchant's magnetic, bar code, and/or radio-frequency card reader.
It is now a common practice to sell such cards to purchasers with
the activation taking place at the merchant counter at the time of
sale. Moreover, as a result of this practice, the merchant reduces
his overhead because the value of the inactivated stored value
cards is not payable to the wholesale vendor of the cards until the
card itself is actually distributed by the merchant at the point of
sale.
[0005] Stored value cards are often sold mounted in or on some sort
of card carrier and/or protective display package. These cards,
however, may still be susceptible to theft and/or fraud due to
tampering. For example, the confidential code may be pre-accessed
by a malicious person such that the purchased value of the
unsuspecting legitimate purchaser may be later stolen. In order to
reduce the chance of theft or fraud, it is typically the practice
that a stored value card is not activated until purchase. That is,
upon sale of a stored value card to a purchaser, the merchant
electronically activates the stored value card with a specific
balance paid for by the purchaser, and the purchaser may utilize
the stored value using a confidential code provided in the card.
Additionally, a database containing activation codes and balance
data is typically maintained by a processing company, which is
notified electronically by the merchant when the card has been
activated. Alternatively, the processing company may perform the
activation of the card upon receiving an electronic message from
the merchant that the particular card has been purchased.
[0006] In the purchasing of stored value cards, it is often
desirable to purchase more than one card in a single purchase. As
such, stored value card multipacks (Le. display packages containing
multiple cards) have been created. Such multipacks allow a
purchaser to purchaser more than one card in a single purchase,
such as several cards each having a relatively low redemption value
as opposed to a single card having a high value. However, there are
additional complexities in the packaging, activation, data-keeping,
and fraud protection of such stored value card multipacks, and one
or more of these tasks is typically performed manually during the
manufacturing of the stored value card multipacks which may enable
fraud and theft at the manufacturing stage. Further, while stored
value card multipacks have been manufactured with data printed on
an inside surface of the packaging, such data has been packaging
inventory control data that was not used in automating the
manufacturing of the stored value card multipacks.
[0007] As discussed above, fraud and theft is a common problem
associated with stored value cards and, unfortunately, may occur
during the manufacturing and/or packaging of the cards. For
example, it is possible that the bar codes of the individual cards
may be copied and produced on duplicate cards. As such, there is a
need for a system that reduces fraud and theft during manufacturing
and packaging of stored value cards, including stored value card
multipacks. Additionally, there is a need to provide a stored value
card with a high degree of fraud protection so that it can be
readily observed if the card has been tampered with.
SUMMARY
[0008] According to an aspect of embodiments of the present
invention, an automated packaging apparatus is configured to
sequentially place cards, such as gift cards or debit cards, of a
plurality of cards into a card package (i.e. a multipack).
According to aspects of embodiments of the present invention,
systems, apparatuses, and methods for constructing a card multipack
reduce manual handling and packaging errors, packaging time and
cost, and opportunity for fraud and theft.
[0009] According to another aspect of embodiments of the present
invention, an automated system for constructing card multipacks is
configured to read bar codes from stored value cards, compare and
verify the bar codes with predetermined codes of a data file, and
package and seal the stored value cards in the card multipacks,
each being performed in-line in the automated system without human
interaction. According to an aspect of embodiments of the present
invention, an automated system for constructing card multipacks is
configured to read at least one card bar code in-line from at least
one stored value card and a carrier bar code from a corresponding
carrier, to compare and verify the at least one card bar code and
the carrier bar code with predetermined codes of a data file
linking, or associating, the at least one card bar code and the
corresponding carrier bar code, and to package and seal the at
least one stored value card together with the corresponding carrier
to form a card multipack. According to an aspect of embodiments of
the present invention, an automated system for constructing card
multipacks is configured to read card bar codes in-line from a
plurality of stored value cards, to compare and verify the
plurality of card bar codes with predetermined codes of a data
file, that is, by a process of bicapture or in-line compare, and to
package and seal the plurality of stored value cards to form a card
multipack. The card bar codes may be linked or associated with a
carrier bar code, which may also be read and verified in-line, or
the card bar codes may include a parent card bar code linked or
associated with at least one child card bar code.
[0010] According to another aspect of embodiments of the present
invention, an automated system for constructing card multipacks is
configured to sequentially place on a carrier a plurality of stored
value cards, while reading and verifying a card bar code of each of
the plurality of stored value cards with a respective predetermined
code of a data file in-line before a next one of the stored value
cards is stacked on the previous one of the stored value cards, and
to package and seal the plurality of stored value cards to form a
card multipack.
[0011] According to another aspect of embodiments of the present
invention, a card multipack for packaging a plurality of stored
value cards is compact due to the stored value cards being stacked
and overlapped with one another.
[0012] According to another aspect of embodiments of the present
invention, a method of constructing a card multipack reduces manual
handling and verification with a database, packaging errors, and
fraud. A method of constructing a card multipack includes
automatically reading card bar codes from stored value cards and
carrier bar codes, automatically verifying the card bar codes with
predetermined codes of a data file linking, or associating, the
card bar codes to corresponding carrier bar codes, and packaging
the stored value cards together with the corresponding carriers to
form card multipacks. According to one aspect, the method includes
packaging a plurality of the stored value cards in each of the card
multipacks. According to an aspect of embodiments of the present
invention, an automated system and method is provided for packaging
a plurality of stored value cards in-line in the automated system
for any style of carrier or package containing any number of stored
value cards.
[0013] According to one embodiment of the present invention, an
automated system for constructing card multipacks includes: a
movable conveyor including a plurality of tooling plates, each
configured to receive a height adjusting member; a first carrier
placing station configured to place a first carrier portion of a
carrier on a tooling plate of the plurality of tooling plates; a
first card placing station configured to place a first stored value
card on the first carrier portion; a first data capture station
configured to read a first card bar code of the first stored value
card in-line in the automated system; and a software system adapted
to verify the first card bar code with a data file.
[0014] In one embodiment, the first data capture station comprises
a first camera configured to create a first image of the first card
bar code, and the software system is adapted to verify the first
card bar code using the first image.
[0015] In one embodiment, the automated system further includes
another data capture station configured to read a carrier bar code
of the carrier, wherein the software system is further adapted to
verify the carrier bar code with the data file. The automated
system may further include a second carrier placing station between
the first data capture station and the another data capture
station, the second carrier placing station configured to place a
second carrier portion of the carrier on the first stored value
card subsequent to the first data capture station reading the first
card bar code, the second carrier portion including the carrier bar
code.
[0016] In one embodiment, the automated system further includes: a
second card placing station configured to place a second stored
value card on the first carrier portion subsequent to the first
data capture station reading the first card bar code; and a second
data capture station configured to read a second card bar code of
the second stored value card in-line in the automated system, and
the software system is further adapted to verify the second card
bar code with the data file. The second data capture station may
include a second camera configured to create a second image of the
second card bar code, and the software system may be adapted to
verify the second card bar code using the second image. The second
card placing station may be configured to place the second stored
value card on the first stored value card such that the second
stored value card at least partially covers the first card bar
code.
[0017] In one embodiment, the automated system further includes a
sealing station configured to seal the carrier, and the first data
capture station is configured to read the first card bar code
between the first card placing station and the sealing station. The
software system may be adapted to verify the first card bar code
in-line in the automated system and provide an output before the
sealing station seals the carrier. The height adjusting portion may
be configured to support the first carrier portion and adjust a
height of the carrier to seal the carrier.
[0018] In one embodiment, the first carrier placing station is
further configured to place another first carrier portion of
another carrier on the conveyor, the first card placing station is
further configured to place another first stored value card on the
another first carrier portion, the first data capture station is
further configured to read another first card bar code of the
another first stored value card in-line in the automated system,
and the software system is further adapted to verify the another
first card bar code with the data file. Each of the plurality of
tooling plates may be configured to support the first carrier
portion and the another first carrier portion.
[0019] In one embodiment, the software system is further adapted to
create another data file including information of the first card
bar code.
[0020] In one embodiment, the system includes a plurality of card
placing stations configured to sequentially place a plurality of
stored value cards on the carrier.
[0021] In one embodiment, the data capture stations are configured
to read the card bar codes and the software system is configured to
verify the codes with the data file in-line in the automated system
without human interaction.
[0022] In one embodiment, the card multipacks are gift card
multipacks.
[0023] In one embodiment, the system further includes a second
carrier placing station between the first carrier placing station
and the at least one card placing station, the second carrier
placing station being configured to place a first carrier shell of
the carrier on the first carrier portion such that a recessed
portion of the first carrier shell protrudes through an opening of
the first carrier portion. In one embodiment, the system further
includes a third carrier placing station between the at least one
card placing station and a sealing station for sealing the card
multipack, the third carrier placing station being configured to
place a second carrier portion of the carrier over the first
carrier shell and the at least one stored value card.
[0024] According to another embodiment of the present invention, a
software system for use with an automated system for constructing
card multipacks is adapted to compare and verify a plurality of
card bar codes of a plurality of stored value cards in-line in the
automated system using a data file including the plurality of card
bar codes.
[0025] In one embodiment, the software system is further adapted to
create another data file including information of the plurality of
card bar codes. In one embodiment, the software system is further
adapted to output a warning of non-verification of a card bar code
of the plurality of card bar codes.
[0026] According to another embodiment of the present invention, a
card multipack includes: a carrier; a first stored value card
supported on the carrier and including a first card bar code; and a
second stored value card supported on the carrier such that the
second stored value card at least partially covers the first card
bar code, the second stored value card including a second card bar
code.
[0027] According to another embodiment of the present invention, a
method of constructing a card multipack using an automated system
includes: placing a first carrier portion of a carrier on a
conveyor of the automated system using a first carrier placing
station of the automated system, the conveyor including a plurality
of tooling plates, each configured to receive a height adjusting
member; placing a plurality of stored value cards on the first
carrier portion using at least one card placing station of the
automated system; reading a plurality of card bar codes of the
plurality of stored value cards in-line using a data capture
station of the automated system; and creating a data file including
the card bar codes using a software system of the automated
system.
[0028] In one embodiment, the method further includes: reading a
carrier bar code of the carrier in-line using another data capture
station of the automated system; and verifying the carrier bar code
with the data file using the software system of the automated
system.
[0029] In one embodiment, the method further includes: placing a
second stored value card on the first carrier portion using a
second card placing station of the automated system subsequent to
reading the first card bar code; reading a second card bar code of
the second stored value card in-line using a second data capture
station of the automated system; and verifying the second card bar
code with the data file using the software system of the automated
system. Placing the second stored value card on the first carrier
portion may include placing the second stored value card on the
first stored value card such that the second stored value card at
least partially covers the first card bar code.
[0030] In one embodiment, reading the first card bar code may
include creating an image of the first card bar code using a first
camera.
[0031] In one embodiment, the method further includes sealing the
card multipack in-line using the automated system subsequent to
verifying the first card bar code.
[0032] In one embodiment, reading the card bar codes and reading
the carrier bar code are performed subsequent to placing the stored
value cards on the first carrier portion, and the method further
includes sealing the card multipack subsequent to reading the card
bar codes and reading the carrier bar code.
[0033] In one embodiment, reading each of the card bar codes
includes creating an image of each of the card bar codes using a
respective camera, and reading the carrier bar code includes
creating an image of the carrier bar code using another camera. The
method may further include placing a second carrier portion
including the carrier bar code on the stored value cards using a
second carrier placing station of the automated system subsequent
to reading the card bar codes and prior to reading the carrier bar
code.
[0034] In one embodiment, the method further includes sealing the
card multipack in-line using the automated system.
[0035] In one embodiment, placing a plurality of stored value cards
on the carrier includes sequentially placing the plurality of
stored value cards on the carrier. The method may further include
placing an adhesive on at least one stored value card (e.g., on
each of the stored value cards) of the plurality of stored value
cards.
[0036] In one embodiment, the method further includes placing a
first carrier shell on the first carrier portion such that a
recessed portion of the first carrier shell protrudes through an
opening of the first carrier portion, and placing the stored value
cards on the carrier includes placing the stored value cards in the
recessed portion of the first carrier shell. The method may further
include placing a second carrier portion on the stored value cards
over the first carrier shell prior to sealing the card
multipack.
[0037] Placing the stored value cards on the carrier may include
utilizing a vacuum device. In one embodiment, the method further
includes tamper-proofing the card package such that the card
multipack cannot be opened without visible damage.
[0038] According to another embodiment of the present invention, an
automated apparatus for constructing card multipacks containing a
plurality of cards includes a plurality of stations and a conveyer
movable for conveying the card multipacks between the stations,
wherein the plurality of stations includes: a carrier placing
station at a first end of the apparatus and configured to place a
carrier on the conveyor; a first shell placing station configured
to place a first shell on the carrier such that a recessed portion
of the first shell protrudes through an opening of the carrier; a
plurality of card placing stations configured to sequentially place
each of the plurality of cards in the recessed portion of the first
shell; and a sealing station at a second end of the apparatus
opposite the first end, the sealing station being configured to
seal the multipack for containing the plurality of cards in the
recessed portion of the first shell, wherein the first shell
placing station is between the carrier placing station and the
sealing station, and the card placing stations are between the
first shell placing station and the sealing station.
[0039] In one embodiment, the plurality of stations further
includes a second shell placing station between the plurality of
card placing stations and the sealing station, the second shell
placing station being configured to place a second shell on the
carrier over the first shell and the plurality of cards.
[0040] The card placing stations may include vacuum devices for
placing the cards. Similarly, the carrier placing station and the
shell placing stations may include vacuum devices for placing the
carriers and the shells. In one embodiment, the apparatus further
includes a dispensing device configured to dispense an adhesive on
at least one of the plurality of cards, such as on each of the
plurality of cards.
[0041] In one embodiment, the apparatus further includes a
plurality of cameras configured to create an image of respective
ones of the plurality of cards and the carrier between the
plurality of card placing stations and the sealing station. The
apparatus may further include a software system adapted to compare
and verify card bar codes and a carrier bar code with predetermined
codes of a data file using the image, the card bar codes on
corresponding ones of the plurality of cards being associated with
the carrier bar code on the carrier.
[0042] Additional aspects and/or advantages of embodiments of the
present invention are set forth in the following description and
accompanying drawings, or may be obvious in view thereof to those
skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] The above and other features and advantages will become more
apparent to those of ordinary skill in the art by describing in
detail some exemplary embodiments of the present invention with
reference to the attached drawings, in which:
[0044] FIG. 1 is a schematic diagram of an automated system for
constructing card multipacks according to an embodiment of the
present invention:
[0045] FIG. 2 is a front view of a card multipack constructed using
the automated system for constructing card multipacks of FIG. 1,
according to an embodiment of the present invention;
[0046] FIG. 3A is a rear view of the card multipack of FIG. 2,
shown in an unsealed state, and FIG. 3B is a rear view of the card
multipack of FIG. 2, shown in a sealed state;
[0047] FIG. 4A is a front view of a card multipack according to
another embodiment, and FIG. 4B is a rear view of the card
multipack of FIG. 4A, shown in a sealed state;
[0048] FIG. 5 is a front schematic view of a carrier placing
station of the automated system for constructing card multipacks of
FIG. 1, according to an embodiment of the present invention;
[0049] FIG. 6 is a front schematic view of a shell placing station
of the automated system for constructing card multipacks of FIG. 1,
according to an embodiment of the present invention;
[0050] FIG. 7 is a front schematic view of a card placing station
of the automated system for constructing card multipacks of FIG. 1,
according to an embodiment of the present invention;
[0051] FIG. 8 is a front schematic, view of a data capture station
of the automated system for constructing card multipacks of FIG. 1,
according to an embodiment of the present invention;
[0052] FIG. 9 is a front schematic view of a sealing station of the
automated system for constructing card multipacks of FIG. 1,
according to an embodiment of the present invention;
[0053] FIG. 10 is a front schematic view of a transporting station
of the automated system for constructing card multipacks of FIG. 1,
according to an embodiment of the present invention;
[0054] FIG. 11 is a flowchart showing tasks of a method of
constructing a card multipack using the automated system for
constructing card multipacks of FIG. 1;
[0055] FIG. 12 is a rear perspective view of a carrier base of a
card multipack to be placed on a conveyer of the automated system
for constructing card multipacks of FIG. 1;
[0056] FIG. 13 is a rear perspective view of a first carrier shell
of a card multipack placed on the carrier base of FIG. 12;
[0057] FIGS. 14-17 are rear perspective views of stored value cards
placed on the first carrier shell of FIG. 13;
[0058] FIG. 18 is a rear perspective view of a second carrier shell
of a card multipack placed over the stored value cards of FIGS.
14-17 and sealed with the carrier base and the first carrier
shell;
[0059] FIG. 19 is a schematic diagram of an automated system for
constructing card multipacks according to another embodiment of the
present invention;
[0060] FIG. 20 is a front schematic view of a first sealing station
of the automated system for constructing card multipacks of FIG.
19, according to an embodiment of the present invention;
[0061] FIG. 21 is a front schematic view of a first transporting
station of the automated system for constructing card multipacks of
FIG. 19, according to an embodiment of the present invention;
[0062] FIG. 22 is a front schematic view of a second sealing
station of the automated system for constructing card multipacks of
FIG. 19, according to an embodiment of the present invention;
[0063] FIG. 23 is an exploded rear view of a card multipack
constructed using the automated system for constructing card
multipacks of FIG. 19, according to an embodiment of the present
invention; and
[0064] FIG. 24 is a flowchart showing tasks of a method of
constructing a card multipack using the automated system for
constructing card multipacks of FIG. 19.
DETAILED DESCRIPTION
[0065] Some exemplary embodiments will now be described more fully
hereinafter with reference to the accompanying drawings; however,
embodiments of the present invention may be embodied in different
forms and should not be construed as limited to the exemplary
embodiments illustrated and set forth herein. Rather, these
exemplary embodiments are provided by way of example for
understanding of the invention and to convey the scope of the
invention to those skilled in the art.
[0066] With reference to FIG. 1, an automated system 100 for
constructing card multipacks according to one embodiment of the
present invention includes a movable conveyor 102, a first carrier
placing station 110, a second carrier placing station 120, a first
card placing station 130, a second card placing station 140, a
third card placing station 150, a fourth card placing station 160,
a data capture station 170A, a third carrier placing station 180,
and a sealing station 190. In one embodiment, the data capture
station 170A is a first data capture station, and the system 100
further includes a second data capture station 170B, a third data
capture station 170C, a fourth data capture station 170D, and a
fifth data capture station 170E. The system 100, according to an
embodiment, further includes a computer 176 and an associated
software system, as described later herein. In one embodiment, the
system further includes a transporting station 195 configured to
move the sealed card multipacks to a receiving bin 198. The
conveyor 102, in one embodiment, is movable between each of the
stations and devices shown and described above.
[0067] While the system 100 shown in FIG. 1 including each of the
stations and devices described above is one embodiment of the
present invention, the present invention is not limited thereto.
For example, in other embodiments, one or more of the stations or
devices of the system 100 shown in FIG. 1 may be absent and/or
additional stations or devices may be added. For example, in one
alternative embodiment, the system may have any other desired
number of card placing stations rather than four. In another
embodiment, for example, where a constructed card multipack has
only two carrier portions (e.g., a blisterless paper-to-paper
package), the second carrier placing station 120 may be omitted.
Further, while in one embodiment of the present invention, the
stations and devices of the system 100 shown in FIG. 1 are arranged
in the sequence shown relative to one another, the present
invention is not limited thereto. That is, the stations and devices
of the system 100 may be arranged in any other suitable sequence
relative to one another. Further, in one embodiment, as shown in
FIG. 1, the stations and devices of the system 100 are arranged in
an assembly line form, and the conveyor 102 is configured to move
the card multipacks 10 from one station or device to the next.
[0068] With reference to FIGS. 2-33, a card multipack 10 according
to one embodiment of the present invention is shown. The card
multipack 10, for example, may be constructed using the automated
system 100. In FIG. 2, the card multipack 10 is shown in a sealed
state containing, for example, four stored value cards 12, that is,
a first stored value card 12a, a second stored value card 12b, a
third stored value card 12c, and a fourth stored value card 12d. As
used herein, the term "stored value card" refers to any card having
a value stored on or associated with the card, including, but not
limited to, gift certificates or gift cards, prepaid credit cards,
and prepaid phone cards. FIG. 3A shows the card multipack 10 in an
unfolded state and shows each of the stored value cards 12 having a
card bar code 14, that is, a first card bar code 14a on the first
stored value card 12a, a second card bar code 14b on the second
stored value card 12b, a third card bar code 14c on the third
stored value card 12c, and a fourth card bar code 14d on the fourth
stored value card 12d. Further, in one embodiment, the stored value
cards 12 may have magnetic stripes which may be used for activation
and/or redemption, for example. In one embodiment, as also shown in
FIG. 3A, the card multipack 10 includes a carrier base 20 and a
first carrier shell 25, or blister, holding the stored value cards
12. The card multipack 10, in one embodiment, has a second carrier
portion 26 having a carrier bar code 26a on an outer surface, as
shown in FIG. 3B. The card multipack 10 is shown in a sealed state
in FIG. 3B. However, embodiments of a card multipack according to
the present invention are not limited to the configuration shown in
FIGS. 2-3B. In another embodiment, for example, with reference to
FIGS. 4A and 4B, in a card multipack 10', the first carrier shell
25, or blister, is omitted, and a carrier base 20' may not have an
opening (see FIG. 12) for receiving the first carrier shell 25 such
that the stored value cards 12 may be supported directly on the
carrier base 20'. In one embodiment, each of the card bar codes 14
is linked to the carrier bar code 26a to be activated therewith.
Alternatively, the second carrier portion may have a window (not
shown) through which the card bar code 14 of one of the stored
value cards 12, i.e. a parent card is readable, or scannable, after
the card multipack 10 has been sealed to activate other ones of the
stored value cards 12, i.e. child cards. Also, according to
embodiments of the present invention, the number of stored value
cards in each card multipack is not limited to any particular
number, and the number of cards in each card multipack may be four,
five, or ten, for example.
[0069] As shown in FIG. 3A, the stored value cards 12 may be
placed, or stacked, on one another in the card multipack 10 in an
overlapping manner such as to at least partially cover the
respective card bar code 14 of the one or more overlapped stored
value cards 12. As such, the card multipack 10 may have a compact
size. In an embodiment, the respective card bar code 14 of each of
the one or more overlapped stored value cards 12 is read by one of
the data capture stations prior to a subsequent one of the stored
value cards 12 being placed.
[0070] With reference to FIG. 5, in one embodiment, the conveyor
102 is made up of a pair of chains 103 driven by a motor, for
example, and a plurality of tooling plates 104 coupled between the
pair of chains 103 but, alternatively, may include a belt or any
other movable conveying device known in the art. Further, the
conveyor 102 may be configured to provide a stepwise or
intermittent movement of the tooling plates 104 to each of the
stations. In an embodiment, each of the tooling plates 104 may have
alignment portions 105 (e.g., pins or protrusions) (see FIG. 9) to
align the carrier base 20, such as around a perimeter thereof, and
may further include one or more recesses 106 to receive the first
carrier shell 25. In an embodiment, the tooling plate 104 includes
a height adjusting portion 108 (see FIG. 9) on an upper surface of
the tooling plate 104 to adjust for a thickness of the card
multipack 10 or one or more components thereof, thereby
facilitating sealing of the card multipack 10. In an embodiment,
the height adjusting portion 108 may be a removable or
interchangeable insert or gasket. In one embodiment, the height
adjusting portion 108 is a fiberglass-reinforced or
fabric-reinforced silicone sheet having a thickness of 3/32'',
which may be adhered to the upper surface of the tooling plate 104.
However, embodiments of the present invention are not limited
thereto. In one embodiment, the system 100 is configured to perform
an operation concurrently on a plurality of the card multipacks 10
at each of the stations. As such, each of the tooling plates 104
may include a plurality (e.g., four, five, or ten, for example) of
the recesses 106, as shown.
[0071] With further reference to FIG. 5, the first carrier placing
station 110 is configured to place the carrier base 20 on the
conveyor 102. For example, the timing of the conveyor 102 and the
first carrier placing station 110 may be set relative to one
another by any suitable device or method known in the art. In one
embodiment, the first carrier placing station 110 includes a
holding rack 112 for holding a stack of the carrier bases 20 to be
placed on the conveyor 102. Further, in one embodiment, the first
carrier placing station 110 includes one or more placing mechanisms
114 configured to grab one of the carrier bases 20 from the holding
rack 112 and place the carrier base 20 on the tooling plate 104 of
the conveyor 102. In one embodiment, the placing mechanisms 114 are
connected to vacuum or suction lines, wherein suction is applied
from a suction-generating device 115 (e.g., a vacuum pump), for
grabbing and holding the carrier base 20 and is released for
placing the carrier base 20 on the conveyor 102. Further, in one
embodiment, the placing mechanisms 114 are coupled to an arm 116
that is pivotable about a shaft 118, and the arm 116 is pivotable
back and forth at a desired rate for grabbing and placing the
carrier bases 20 on the conveyor 102. Further, the placing
mechanisms 114 may be rotatably coupled to the arm 116 about a
pivot 119. However, embodiments of the first carrier placing
station 110 of the present invention are not limited to the
above-described and shown configuration, but rather, may have any
other suitable configuration for placing the carrier base 20 on the
conveyor 102.
[0072] With reference to FIG. 6, the second carrier placing station
120 is configured to place the first carrier shell 25 on the
carrier base 20. In one embodiment, the second carrier placing
station 120 includes a holding rack 122 for holding a stack of the
first carrier shells 25 to be placed on the carrier bases 20.
Further, in one embodiment, the second carrier placing station 120
includes one or more placing mechanisms 124 configured to grab one
of the first carrier shells 25 from the holding rack 122 and place
the first carrier shell 25 on the carrier base 20. In one
embodiment, the first carrier shell 25 is placed on the carrier
base 20 such that a recessed portion of the first carrier shell 25
protrudes through an opening 24 (see FIG. 12) formed in the carrier
base 20. In one embodiment, the placing mechanisms 124 are
connected to vacuum or suction lines, wherein suction is applied
from a suction-generating device 125 (e.g., a vacuum pump) for
grabbing and holding the first carrier shell 25 and is released for
placing the first carrier shell 25 on the carrier base 20. Further,
in one embodiment, the placing mechanisms 124 are coupled to an arm
126 that is pivotable about a shaft 128, and the arm 126 is
pivotable back and forth at a desired rate for grabbing and placing
the first carrier shells 25 on the carrier bases 20. Further, the
placing mechanisms 124 may be rotatably coupled to the arm 126
about a pivot 129. Embodiments of the second carrier placing
station 120 of the present invention are not limited to the
above-described embodiment, but rather, may have any other suitable
configuration for placing the first carrier shells 25 on the
carrier bases 20.
[0073] With reference to FIG. 7, the first card placing station 130
is configured to place the first stored value card 12a in the first
carrier shell 25. In one embodiment, the first card placing station
130 is configured similarly or the same as the second carrier
placing station 120 described above. The first card placing station
130, in one embodiment, includes a holding rack 132 for holding a
stack of the first stored value cards 12a to be placed in the first
carrier shells 25. Further, in one embodiment, the first card
placing station 130 includes one or more placing mechanisms 134
configured to grab one of the first stored value cards 12a from the
holding rack 132 and place the first stored value card 12a in the
first carrier shell 25. In one embodiment, the placing mechanisms
134 are connected to vacuum or suction lines, wherein suction is
applied from a suction-generating device 135 (e.g., a vacuum pump)
for grabbing and holding the first stored value card 12a and is
released for placing the first stored value card 12a in the first
carrier shell 25. Further, in one embodiment, the placing
mechanisms 134 are coupled to an arm 136 that is pivotable about a
shaft 138, and the arm 136 is pivotable back and forth at a desired
rate for grabbing and placing the first stored value cards 12a in
the first carrier shells 25. Further, the placing mechanisms 134
may be rotatably coupled to the arm 136 about a pivot 139.
Embodiments of the first card placing station 130 of the present
invention are not limited to the above-described embodiment, but
rather, may have any other suitable configuration for placing the
first stored value cards 12a in the first carrier shells 25.
[0074] In one embodiment, the second card placing station 140, the
third card placing station 150, and the fourth card placing station
160 are each configured similar to or the same as the first card
placing station 130 described above and shown in FIG. 7, and
therefore will not be described in further detail. Each of the
second card placing station 140, the third card placing station
150, and the fourth card placing station 160 are configured to
place one of the stored value cards 12 on a previously placed one
of the stored value cards 12 in the first carrier shell 25. As
described above, in other embodiments of the system 100, there may
be additional card placing stations or fewer than the four card
placing stations shown in FIG. 1. In one embodiment, there may be
only one card placing station. Further, in one embodiment, one or
more of the card placing stations may be configured to place more
than one of the stored value cards 12 in the first carrier shell
25. Further, the card placing stations 130, 140, 150, 160, in one
embodiment, are configured similarly to the carrier placing
stations 110, 120, 180, and, in one embodiment, one or more of the
carrier placing stations 110. 120, 180 may be utilized as a card
placing station or vice versa.
[0075] With further reference to FIG. 7, the system 100, in one
embodiment, includes one or more adhesive dispensing devices 145.
The adhesive dispensing devices 145, in one embodiment, are
configured to dispense an adhesive on one or more of the stored
value cards 12 in order to maintain the stored value cards 12 in
place once the stored value cards 12 are placed in the first
carrier shell 25. In one embodiment, the adhesive dispensing device
145 includes an adhesive supply tube 146 through which the adhesive
is supplied via a pump or other suitable device. Further, the
adhesive may be dispensed through a nozzle or other suitable
device. The one or more adhesive dispensing devices 145, in one
embodiment, may be located before or after one or more of the card
placing stations 130, 140, 150, 160. Also, in an embodiment, one or
more adhesive dispensing devices may be located and configured to
dispense an adhesive on one or more of the carrier portions.
[0076] With reference to FIG. 8, the first data capture station
170A, in one embodiment, is configured to read the first card bar
code 14a from each of the first stored value cards 12a placed in
the first carrier shell 25. The first data capture station 170A, in
one embodiment, includes one or more cameras 172 configured to
create an image of the first card bar codes 14a. In an embodiment,
the camera is Model No. 21445476 manufactured by Basler,
Ahrensburg, Germany. In one embodiment, the first data capture
station 170A further includes at least one illuminating device 174,
such as an LED flash, configured to provide illumination on the
first card bar codes 14a when the one or more cameras 172 capture
the image. In one embodiment, the first data capture station 170A
is configured to read the first card bar code 14a at a location
between the first card placing station 130 and the second card
placing station 140 before the second stored value card 12b is
placed on the first stored value card 12a. In one embodiment, as
shown, the first data capture station 170A includes a plurality
(e.g., four, five, or ten, for example) of the cameras 172
configured to concurrently create images of the respective first
card bar codes 14a on each of the tooling plates 104.
[0077] In one embodiment, each of the second to fifth data capture
stations 170B, 170C, 170D, 170E may be configured the same or
similarly to the first data capture station 170 and, therefore,
will not be described further. In one embodiment, the second data
capture station 170B is configured to read the second card bar code
14b at a location between the second card placing station 140 and
the third card placing station 150 before the third stored value
card 12c is placed on the second stored value card 12b, the third
data capture station 170C is configured to read the third card bar
code 14c at a location between the third card placing station 150
and the fourth card placing station 160 before the fourth stored
value card 12d is placed on the third stored value card 12c, the
fourth data capture station 170D is configured to read the fourth
card bar code 14d at a location between the fourth card placing
station 160 and the third carrier placing station 180 before the
second carrier portion 26 is placed over the fourth stored value
card 12d, and the fifth data capture station 170E is configured to
read the carrier bar code 26a at a location after the second
carrier portion 26 has been placed by the third carrier placing
station 180.
[0078] With further reference to FIG. 8, the system 100 further
includes a computer 176 including a software system adapted to
compare and verify each of the card bar codes 14 with those of a
data file associating, or linking, each of the card bar codes 14
with the carrier bar code 26a and/or with the other card bar codes
14 of the respective card multipack 10. In one embodiment, the data
file associating, or linking, each of the card bar codes 14 is
preexisting, and the system 100 compares and verifies the card bar
codes 14 in-one after each of the respective stored value cards 12
is placed. In another embodiment, the software system creates the
data file in-line and creates in the data file an association
between each of the card bar codes 14 with the carrier bar code 26a
and/or with the other card bar codes 14 of the respective card
multipack 10. The software system, in one embodiment, verifies the
card bar codes 14 with the data file using the image created by the
respective cameras 172. In one embodiment, the data file is used
for activating all of the stored value cards 12 in the card
multipack 10 (e.g., at a time of purchase) using the carrier bar
code 26a or, alternatively, the card bar code 14 of a parent card
of the stored value cards 12 that is readable through a window of
the carrier due to the association, or linking, in the data
file.
[0079] The third carrier placing station 180 is configured to place
the second carrier portion 26 over the stored value cards 12 and
the first carrier shell 25 before the card multipack 10 is sealed.
The third carrier placing station 180, in one embodiment, is
configured similar to or the same as the second carrier placing
station 120 described above and shown in FIG. 6, and therefore will
not be described in further detail.
[0080] With reference to FIG. 9, the sealing station 190 is
configured to seal the card multipack 10. In one embodiment, the
sealing station 190 is configured to seal the second carrier
portion 26, which may be made of paper or cardboard, to the first
carrier shell 25, which may be made of plastic, and to the carrier
base 20, which may also be made of paper or cardboard. In one
embodiment, the sealing station 190 is configured, to seal the card
multipack 10 using heat and an adhesive which may already be
applied on at least one of the second carrier portion 26 or the
carrier base 20. In one embodiment, the sealing station 190
includes a heat plate 192 configured to press on the second carrier
portion 26. The sealing station 190 may further include a
protective sheet 193, such as a polytetrafluoroethylene (PTFE)
sheet, to prevent the second carrier portion 26 from adhering to
the heat plate 192. The sealing station 190 may further include one
or more devices, such as a hydraulic pump, configured to move the
heat plate 192 downward. In one embodiment, the system 100 may
include brushes 194, such as wire brushes located before the
sealing station 190. The brushes 194 may rotate as the conveyor 102
moves the card multipacks 10 past the brushes 194 to press, or
flatten, and align the second carrier portion 26 and the other
components of the card multipack 10 before sealing. Also, brushes
similar to the brushes 194 may be included between other stations
of the system 10 for pressing and aligning any of various
components of the card multipack 10 between stations.
[0081] With reference to FIG. 10, the transporting station 195 is
configured to transport the sealed card multipacks 10 from the
conveyor 102 to the receiving bin 198. In one embodiment, the
transporting station 195 includes one or more holding mechanisms
196. each configured to grab one of the sealed card multipacks 10
from the conveyor 102 and place the sealed card multipack 10 in a
respective compartment 199 of the receiving bin 198. In one
embodiment, the holding mechanisms 196 are connected to vacuum or
suction lines, wherein suction is applied from a suction-generating
device (e.g., a vacuum pump) for grabbing and holding the sealed
card multipack 10 and is released for placing the sealed card
multipack 10 in the receiving bin 198. Further, in one embodiment,
the holding mechanisms 196 are coupled to an arm 197A that is
movable along a rail 197B in both a direction toward the receiving
bin 198 and back toward the sealing station 190. In an embodiment,
the receiving bin 198 may be provided with a moving belt at a lower
region of the compartments 199 to collect the sealed card
multipacks 10 toward an end of the receiving bin 198 distal from
the transporting station 195.
[0082] With reference to FIG. 11, a method 200 of constructing a
card multipack is shown. While the method 200 is described herein
with respect to the card multipack 10 and the system 100 for
constructing card multipacks described above and shown in FIG. 1,
the method 200, or at least some of the tasks thereof, may be
performed in constructing card multipacks according to other
embodiments of the present invention and/or using an automated
system or apparatus for constructing card multipacks according to
other embodiments of the present invention, such as those described
later herein.
[0083] With reference to FIG. 12, in one embodiment, the method 200
includes a task 210 of placing a carrier base 20 of the card
multipack 10 on the conveyor 102, such as by using the first
carrier placing station 110 of the system 100 described above and
shown in FIG. 5. In one embodiment, the carrier base 20 may be made
of paper of cardboard.
[0084] With reference to FIG. 13, the method 200, in one
embodiment, further includes a task 220 of placing the first
carrier shell 25 on the carrier base 20, such as by using the
second carrier placing station 120 of the system 100 described
above and shown in FIG. 6. In one embodiment, for example, the
carrier base 20 has the opening 24 (see FIG. 12) formed
therethrough, and the first carrier shell 25 has a recessed, or
cupped portion, and is placed on the carrier base 20 such that the
recessed portion protrudes through the opening 24. In an alternate
embodiment, the card multipack 10 does not include the first
carrier shell 25, or blister, and the task 220 may be omitted.
[0085] With reference to FIGS. 14-17, the method 200, in one
embodiment, further includes a task of placing the stored value
cards 12a, 12b, 12c, 12d on the first carrier shell 25, such as by
using the card placing stations 130, 140, 150, 160 of the system
100. As described above, in one embodiment, the stored value cards
12 are stacked on one another such as to at least partially overlap
the card bar code 14 of the previously placed stored value card 12,
thereby constructing the card multipack 10 having a compact size.
In one embodiment, the stored value cards 12 are stacked on the
first carrier shell 25 and compared and verified to a predetermined
sequence stored in the data file of the software system. In one
embodiment, an adhesive may be dispensed onto at least one (e.g. on
each one) of the stored value cards 12 such as using the adhesive
dispensing device 145 described above and shown in FIG. 7, such
that the stored value cards 12 are held in place in the card
multipack 10. In one embodiment, the card bar codes 14 may be
printed on the stored value cards 12 before the stored value cards
12 are placed in the first carrier shell 25. Further, the stored
value cards 12 may be sequentially arranged in the holding rack 132
of the card placing stations 130, 140, 150, 160 according to a
predetermined order (e.g., according to a desired range of values
of the stored value cards 12. Alternatively, the card bar codes 14
may be read and a data file may be created in-line as the stored
value cards are placed in the first carrier shell 25.
[0086] In one embodiment, the method 200 further includes a task of
creating an image of each of the card bar codes 14. In one
embodiment, the method 200 includes a task 230 of placing the first
stored value card 12a on the first carrier shell 25, followed by a
task 240 of creating an image of the first card bar code 14a. In
one embodiment, the one or more cameras 172 of the first data
capture station 170A are used to create one or more respective
images of the first card bar code 14a of one or more of the first
stored value cards 12a. However, the present invention is not
limited thereto and, in other embodiments, the image may be created
by any other suitable device or method. Further, in one embodiment,
the method 200 includes a task 250 of placing the second stored
value card 12b on the first stored value card 12a, followed by a
task 260 of creating an image of the second card bar code 14b. In
one embodiment, one or more cameras of the second data capture
station 170B are used to create one or more respective images of
the second card bar code 14b of one or more of the second stored
value cards 12b. In a task 270 of the method 200, additional stored
value cards 12 (e.g., the third and fourth stored value cards 12c
and 12d) may be placed on the second stored value card 12b, and an
image of each of the card bar codes 14 (e.g., the third and fourth
card bar codes 14c and 14d) of the additional stored value cards 12
may be created.
[0087] The method 200, in one embodiment, further includes a task
of comparing or verifying the card bar codes 14 with a data file
associating the card bar codes 14 with the carrier bar code 26a
and/or with one another. In one embodiment, the data file may be
used with the software system of the computer 176 described above.
That is, the method 200 may include a task 245 of verifying the
first card bar code 14a with the data file after the task 240 of
creating an image of the first card bar code 14a, a task 265 of
verifying the second card bar code 14b with the data file after the
task 260 of creating an image of the second card bar code 14b, and,
similarly, the task 270 including verifying additional card bar
codes (e.g., the third and fourth card bar codes 14c and 14d) after
creating an image of each of the additional card bar codes.
Further, according to an embodiment, the software system performs
the task of verifying the card bar code of each of the stored value
cards concurrently or simultaneously with the task of creating the
image of each of the card bar codes.
[0088] In one embodiment, as shown in FIG. 18, the method 200
further includes a task 275 of placing the second carrier shell 26
over the stored value cards 12, such as using the third carrier
placing station 180 of the system 100. In one embodiment, the
second carrier shell 26 may be another paper of cardboard portion
opposite the carrier base 20.
[0089] The method 200, in one embodiment, further includes a task
280 of creating an image of the carrier bar code 26a. In one
embodiment, one or more cameras of the fifth data capture station
170E are used to create one or mare respective images of the
carrier bar code 26a of one or more of the second carrier portions
26. The method may further include a task 285 of comparing or
verifying the carrier bar code 26a with a data file associating the
card bar codes 14 with the carrier bar code 26a. In an embodiment,
the carrier bar code 26a may be an alphanumeric code. In one
embodiment, the data file may be used with the software system of
the computer 176 described above. In an embodiment, the computer
176 may provide an output, such as a warning when any of the card
bar codes 14 and the carrier bar codes 26a are not verified
correctly with the information in the existing data base. In one
embodiment, the computer 176 may create a data file containing
information of the verification of the card bar codes 14 and the
carrier bar codes 26a, or a data file storing and/or associating
the card bar codes 14 and the respective carrier bar codes 26a.
[0090] In another embodiment, a method of constructing a card
multipack may further include a task of folding the carrier base
20, such as by using a folding station, as described in U.S. patent
application Ser. No. 13/423,105, the entire content of which is
incorporated by reference herein. In an embodiment, the carrier
base 20 may be folded before or after the second carrier shell 26
is placed over the stored value cards 12, or, alternatively, the
second carrier shell 26 may be omitted.
[0091] The method 200, in one embodiment, further includes a task
290 of sealing the card multipack 10, such as using the sealing
station 190 of the system 100. The card multipack 10 is shown in
FIG. 18 in a sealed state. In one embodiment, the task 290 of
sealing the card multipack 10 includes applying heat and/or
pressure to an outer surface of at least one of the carrier base 20
or the second carrier portion 26. An adhesive may be applied to a
portion of at least one of the carrier base 20 or the second
carrier portion 26 prior to being sealed. In one embodiment, after
the card multipack 10 is sealed, the method includes a task of
transporting the sealed card multipack 10 into the receiving bin
198, such as using the transporting station 195 of the system
100.
[0092] In one embodiment, the method 200 may further include a task
of tamper-proofing the card multipack 10. For example, an apparatus
(not shown) may be used for tamper-proofing a card multipack 10
that has already been sealed. Tamper-proofing may include modifying
the sealed card multipack 10 such that the card multipack 10 cannot
be opened without visible damage, for example. In another
embodiment, an apparatus may be used for sealing and
tamper-proofing a card multipack 10.
[0093] While in one embodiment, the method 200 of constructing a
card multipack may include each of the tasks described above and
shown in FIG. 11, in other embodiments of the present invention, in
a method of constructing a card multipack, one or more of the tasks
described above and shown in FIG. 11 may be absent and/or
additional tasks may be performed. Further, in the method 200 of
constructing a card multipack according to one embodiment, the
tasks may be performed in the order depicted in FIG. 11. However,
the present invention is not limited thereto and, in a method of
constructing a card multipack according to other embodiments of the
present invention, the tasks described above and shown in FIG. 11
may be performed in any other suitable sequence.
[0094] With reference to FIG. 19, an automated system 400 for
constructing card multipacks according to another embodiment of the
present invention includes a movable conveyor including a first
conveyor 402A and a second conveyor 4028, a first carrier placing
station 410, a first card placing station 420, a second card
placing station 430, a third card placing station 440, a fourth
card placing station 450, a second carrier placing station 460, a
data capture station 470A, a third carrier placing station 480, a
first sealing station 490, a first transporting station 492, and a
second sealing station 495. In one embodiment, the data capture
station 470A is a first data capture station, and the system 400
further includes a second data capture station 4708, a third data
capture station 470C, a fourth data capture station 470D, and a
fifth data capture station 470E. The system 400, according to an
embodiment, further includes a computer 476 and an associated
software system. In one embodiment, the system further includes a
second transporting station 496 configured to move the sealed card
multi ticks to a receiving bin 498. The conveyor, in one
embodiment, is movable between each of the stations and devices
shown and described above. Further, in one embodiment, each of the
first conveyor 402A and the second conveyor 402B may be configured
similarly to the conveyor 102 described above including a pair of
chains and a plurality of tooling plates but, alternatively, may
include a belt or any other movable conveying device known in the
art.
[0095] While the automated system 400 shown in FIG. 19 including
each of the stations and devices described above is one embodiment
of the present invention, the present invention is not limited
thereto. For example, in other embodiments, one or more of the
stations or devices of the automated system 400 shown in FIG. 19
may be absent and/or additional stations or devices may be added.
For example, in one alternative embodiment, the automated system
may have any other desired number of card placing stations rather
than four. Also, in constructing a particular card multipack, such
as the card multipack shown in FIG. 23 including three stored value
cards, one or more of the stations (e.g., one or more of the card
placing stations) of the system 400 may not be utilized. Further,
while in one embodiment of the present invention, the stations and
devices of the system 400 shown in FIG. 19 are arranged in the
sequence shown relative to one another, the present invention is
not limited thereto. That is, the stations and devices of the
system 400 may be arranged in any other suitable sequence relative
to one another.
[0096] With reference to FIG. 19, the first, second, and third
carrier placing stations 410, 460, 480 may be configured the same
or similarly as the first, second, and third carrier placing
stations 110, 120, 180 of the system 100 described above, and,
similarly, the first, second, third, and fourth card placing
stations 420, 430, 440, 450 may be configured the same or similarly
as the first, second, third, and fourth card placing stations 130,
140, 150, 160 of the system 100 described above. Therefore, further
description of these components of the system 400 will not be
provided. Also, the system 400 may include one or more adhesive
dispensing devices similar to the adhesive dispensing devices 145
described above and configured to dispense adhesive on one or more
of the stored value cards or carrier portions of the constructed
card multipack.
[0097] Each of the first to fourth data capture stations 470A,
470B, 470C, 470D, according to an embodiment, includes one or more
cameras, such as the cameras 172 described above and configured to
create an image of one or more card bar codes 514a, 514b, 514c of
one or more stored value cards 512a, 512b, 512c of a card multipack
500 (see FIG. 23). In one embodiment, each of the first to fourth
data capture stations 470A, 470B, 470C, 470D further includes at
least one illuminating device (not shown), such as an LED flash,
configured to provide illumination on the card bar codes 514a,
514b, 514c when the camera captures the image thereof. The fifth
data capture station 470E may be configured the same or similarly
as the first to fourth data capture stations 470A, 470B, 470C, 470D
and is located for capturing an image of a carrier bar code 516 of
the card multipack 500. In one embodiment, the first data capture
station 470A is configured to read the first card bar code 514a of
the first stored value card 512a at a location between the first
card placing station 420 and the second card placing station 430
before the second stored value card 512b is placed on the first
stored value card 512a, the second data capture station 470B is
configured to read the second card bar code 514b of the second
stored value card 512b at a location between the second card
placing station 430 and the third card placing station 440 before
the third stored value card 512c is placed on the second stored
value card 512b, the third data capture station 470C is configured
to read the third card bar code 514c of the third stored value card
512c at a location between the third card placing station 440 and
the fourth card placing station 450 before a fourth stored value
card is placed on the third stored value card 512c, the fourth data
capture station 470D is configured to read a fourth card bar code
of the fourth stored value card at a location between the fourth
card placing station 450 and the second carrier placing station 460
before the second carrier portion 515 is placed over the fourth
stored value card, and the fifth data capture station 470E is
configured to read the carrier bar code 516 at a location after the
second carrier portion 515 has been placed by the second carrier
placing station 460.
[0098] The system 400, in one embodiment, further includes the
computer 476 similar to the computer 176 described above and
including a software system adapted to compare and verify each of
the card bar codes 514a, 514b, 514c with those of a data file
associating, or linking, each of the card bar codes 514a, 514b,
514c with the carrier bar code 516 and/or with the other card bar
codes 514a, 514b, 514c of the respective card multipack 500. In one
embodiment, the data file associating, or linking, each of the card
bar codes 514a, 514b, 514c is preexisting, and the system 400
compares and verifies the card bar codes 514a, 514b, 514c in-line
after each of the respective stored value cards 512a, 512b, 512c is
placed. In another embodiment, the software system creates the data
file in-line and creates in the data file an association between
each of the card bar codes 514a, 514b, 514c with the carrier bar
code 516 and/or with the other card bar codes 514a, 514b, 514c of
the respective card multipack 500. The software system, in one
embodiment, verifies the card bar codes 514a, 514b, 514c with the
data file using the image created by the respective cameras of the
data capture stations.
[0099] With reference to FIG. 20, the first sealing station 490, in
one embodiment, is configured to weld a region of a first carrier
shell of the card multipack 500, which may be made of plastic, to a
region of a second carrier shell of the card multipack 500, which
may be made of plastic. In an embodiment, the welded region may
include a pair of welded regions 520 at opposite sides of the card
multipack 500 to maintain the card multipack 500 in an assembled
state until final sealing at the second sealing station 495. In an
embodiment, the first sealing station 490 includes a welding
portion 540 configured to weld the first and second carrier shells
together to form the welded regions 520. In an embodiment, the
first sealing station 490 further include plates 542 at opposite
sides of the welding portion 540 that are configured to press and
maintain the card multipack 500 in position during the welding
process. The first sealing station 490 may further include one or
more devices such as a hydraulic pump 544 configured to move at
least one of the welding portion 540 and the plates 542
downward.
[0100] With reference to FIG. 21, the first transporting station
492, in one embodiment, is configured similarly to the transporting
station 195 described above and is configured to transport the card
multipacks 500 having the welded portions 520 from the first
conveyor 402A to the second conveyor 402B. In one embodiment, the
first transporting station 492 includes one or more holding
mechanisms 560 each configured to grab one of the card multipacks
500 having the welded portions 520 from the first conveyor 402A and
place the card multipack 500 on the second conveyor 402B. In one
embodiment, the holding mechanisms 560 are connected to vacuum or
suction lines, wherein suction is applied from a suction-generating
device (e.g., a vacuum pump) for grabbing and holding the card
multipack 500 and is released for placing the card multipack 500 on
the second conveyor 402B. Further, in one embodiment, the holding
mechanisms 560 are coupled to an arm 562 that is movable along a
rail 564 in both a direction toward the second conveyor 402B and
back toward the first conveyor 402A.
[0101] With reference to FIG. 22, the second sealing station 495,
in one embodiment, is configured to seal by heating or melting
(e.g., around a perimeter) the first carrier shell of the card
multipack 500, which may be made of plastic, to the second carrier
shell of the card multipack 500, which may be made of plastic. In
an embodiment, the second sealing station 495 includes a heating
device 580 including a heat plate 582 configured to press and heat
or melt the first and second carrier shells together (e.g., around
perimeters thereof) to seal the card multipack 500. In an
embodiment, the second sealing station 495 further includes a
cooling device 585 located after the sealing device 580 and
including a cooling plate, for example, configured to cool the
sealed card multipack 500. The second sealing station 495 may
further include a protective sheet 590, such as a
polytetrafluoroethylene (PTFE) sheet, to prevent the second carrier
shell from adhering to the heat plate 582 or the cooling plate 585.
In an embodiment, the protective sheet 590 is moved between a
supply roll 592 and a winding roll 594 while the second conveyor
402B is moved. The second sealing station 495 may further include
one or more devices such as hydraulic pumps 584 and 586 configured
to move the heat plate 582 and the cooling plate of the cooling
device 585 downward. In an embodiment, the second transporting
station 496 and the receiving bin 498 may be configured the same or
similarly as the transporting station 195 and the receiving bin 198
of the system 100 described above, and, therefore, further
description of these components will not be provided.
[0102] With reference to FIG. 23, the card multipack 500 according
to an embodiment of the present invention is shown. The card
multipack 500, for example, may be constructed using the automated
system 400 described above. The card multipack 500 contains one or
more of the stored value cards 512a, 512b, 512c each having one of
the card bar codes 514a, 514b, 514c. In one embodiment, the card
multipack 500 includes a first carrier shell 502 on which the
stored value cards 512a, 512b, 512c are sequentially placed. The
card multipack 500 further includes a carrier insert 515 placed
over the stored value cards 512a, 512b, 512c and having the carrier
bar code 516 on a surface which, in one embodiment, faces a same
direction as surfaces of the stored value cards 512a, 512b, 512c
having the card bar codes 514a, 514b, 514c and in which the image
of the carrier bar code 516 may be captured by the fifth data
capture station 470E. The carrier bar code 516 is readable, or
scannable, and is located on an exterior of the card multipack 500
after the card multipack 500 has been sealed. In one embodiment the
card multipack 500 further includes a second carrier shell 518
placed over the carrier insert 515 and which may be sealed together
with the first carrier shell 502. In an embodiment, the stored
value cards 512a, 512b, 512c may be placed, or stacked, on one
another in the card multipack 500 in an overlapping manner such as
to at least partially cover the respective card bar code 514a, 514b
of the one or more overlapped stored value cards 512a, 512b. As
such, the card multipack 500 may have a compact size. In an
embodiment, the respective card bar code 514a, 514b of each of the
one or more overlapped stored value cards 512a, 512b is read by one
of the data capture stations prior to a subsequent one of the
stored value cards 512b, 512c being placed. Also, although FIG. 23
shows three cards in the card multipack 500, the number of stored
value cards in each card multipack is not limited to any particular
number, and the number of cards in each card multipack may be four,
five, or ten, for example.
[0103] With reference to FIG. 24, a method 600 of constructing a
card multipack is shown. The method 600, in one embodiment, may be
performed in constructing the card multipack 500 using the system
400 for constructing card multipacks described above and shown in
FIG. 19. However, in other embodiments, the method 600, or at least
some of the tasks thereof, may be performed in constructing card
multipacks according to other embodiments of the present invention
and/or using an automated system or apparatus for constructing card
multipacks according to other embodiments of the present
invention.
[0104] The method 600 includes a task 610 of placing the first
carrier shell 502 of the card multipack 500 on the first conveyor
402A, such as by using the first carrier placing station 410. In
one embodiment, the first carrier shell 502 may be a clam
shell.
[0105] The method 600 further includes a task of placing one or
more of the stored value cards 512a, 512b, 512c on the first
carrier shell 502, such as by using one or more of the card placing
stations 420, 430, 440, 450. In one embodiment, an adhesive may be
dispensed onto at least one of the stored value cards 512a, 512b,
512c, such as by using an adhesive dispensing device. As described
above, in one embodiment, the stored value cards 512a, 512b, 512c
are stacked on one another such as to at least partially overlap
the card bar code 514a, 514b of the previously placed stored value
card 512a, 512b, thereby constructing the card multipack 500 having
a compact size. In one embodiment, the stored value cards 512a,
512b, 512c are stacked on the first carrier shell 502 and compared
and verified to a predetermined sequence stored in the data file of
the software system. In one embodiment, an adhesive may be
dispensed onto at least one (e.g., on each one) of the stored value
cards 512a, 512b, 512c, such that the stored value cards 512a,
512b, 512c are held in place in the card multipack 500. In one
embodiment, the card bar codes 514a, 514b, 514c may be printed on
the stored value cards 512a, 512b, 512c before the stored value
cards 512a, 512b, 512c are placed in the first carrier shell 502.
Further, the stored value cards 512a, 512b, 512c may be
sequentially arranged in the holding rack of each of the respective
card placing stations according to a predetermined order (e.g.,
according to a desired range of values of the stored value cards
512a, 512b, 512c.
[0106] In one embodiment, the method 600 further includes a task of
creating an image of each of the card bar codes 514a, 514b, 514c.
In one embodiment, the method 200 includes a task 620 of placing
the first stored value card 512a on the first carrier shell 502,
followed by a task 630 of creating an image of the first card bar
code 514a. In one embodiment, the one or more cameras of the first
data capture station 470A are used to create one or more respective
images of the first card bar code 514a of one or more of the first
stored value cards 512a. However, the present invention is not
limited thereto and, in other embodiments, the image may be created
by any other suitable device or method. In one embodiment, the
method 600 includes a task 640 of placing the second stored value
card 512b on the first stored value card 512a, followed by a task
650 of creating an image of the second card bar code 514b. In one
embodiment, one or more cameras of the second data capture station
470B are used to create one or more respective images of the second
card bar code 514b of one or more of the second stored value cards
512b. In a task 660 of the method 600, additional stored value
cards (e.g., the third stored value card 512c and a fourth stored
value card) may be placed on the second stored value card 512b, and
an image of each of the card bar codes (e.g., the third card bar
code 514c and a fourth card bar code) of the additional stored
value cards may be created.
[0107] The method 600, in one embodiment, further includes a task
of comparing or verifying the card bar codes 514a, 514b, 514c with
a data file associating the card bar codes 514a, 514b, 514c with
the carrier bar code 516 and/or with one another. In one
embodiment, the data file may be used with the software system of
the computer 476 described above. That is, the method 600 may
include a task 635 of verifying the first card bar code 514a with
the data file after the task 630 of creating an image of the first
card bar code 514a, a task 655 of verifying the second card bar
code 514b with the data file after the task 650 of creating an
image of the second card bar code 514b, and, similarly, the task
660 including verifying additional card bar codes (e.g., the third
card bar code 514c and a fourth card bar code) after creating an
image of each of the additional card bar codes. Further, according
to an embodiment, the software system performs the task of
verifying the card bar code of each of the stored value cards
concurrently or simultaneously with the task of creating the image
of each of the card bar codes.
[0108] The method 600 further includes a task 665 of placing the
carrier insert 515 of the card multipack 500 on the stored value
cards 512a, 512b, 512c, such as by using the second carrier placing
station 460. In one embodiment, the carrier bar code 516 may be
printed on the carrier insert 515 before the carrier insert 515 is
placed on the stored value cards 512. In one embodiment, the
carrier insert 515 may be a parent carrier.
[0109] The method 600, in one embodiment, further includes a task
670 of creating an image of the carrier bar code 516. In one
embodiment, one or more cameras of the fifth data capture station
470E are used to create one or more respective images of the
carrier bar code 516 of one or more of the carrier inserts 515. The
method may further include a task 675 of comparing or verifying the
carrier bar code 516 with a data file associating the card bar
codes 514a, 514b, 514c with the carrier bar code 516. In an
embodiment, the carrier bar code 516 may be an alphanumeric code.
In one embodiment, the data file may be used with the software
system of the computer 476 described above. In an embodiment, the
computer 476 may provide an output, such as a warning when any of
the card bar codes 514, 514b, 514c and the carrier bar codes 516
are not verified correctly with the information in the existing
data base. In one embodiment, the computer 476 may create a data
file containing information of the verification of the card bar
codes 514a, 514b, 514c and the carrier bar codes 516, or a data
file storing and/or associating the card bar codes 514a, 514b, 514c
and the respective carrier bar codes 516.
[0110] The method 600 of constructing a card multipack, according
to one embodiment, further includes a task 680 of placing the
second carrier shell 518 over the carrier insert 515, such as by
using the third carrier placing station 480, and a task 690 of
sealing, the card multipack 500, such as using the first and second
sealing stations 490, 495. In one embodiment, the second carrier
shell 518 may be a clam shell, In one embodiment, the task 690 of
sealing the card multipack 500 includes applying heat and/or
pressure to an outer surface of at least one of the first carrier
shell 502 or the second carrier shell 518. The task 690 may include
first welding regions of the first and second carrier shells 502,
518, such as using the first sealing station 490, and subsequently
sealing the first and second carrier shells 502, 518 about a
perimeter thereof, such as using the second sealing station 495.
That is, the first and second clam shells 502. 518 may be melted,
or heat sealed, together using the second sealing station 495. In
one embodiment, after the card multipack 500 is sealed, the method
includes a task of transporting the sealed card multipack 500 into
the receiving bin 498, such as using the second transporting
station 495 of the system 400. In another embodiment, the method
600 may further include a task of tamper-proofing the card
multipack 500, such as described above with respect to the method
200.
[0111] Although the drawings illustrate the invention as applied to
an automated system for constructing card multipacks containing
stored value cards, it will be apparent that the novel aspects of
the automated system and method of the invention may also be
applied to other applications. For example, aspects of embodiments
of an automated system and method described herein may be applied
to an automated system for constructing packages containing other
cards or other items. Further, it will be apparent to those skilled
in the art that an automated system for constructing card
multipacks may incorporate or embody various combinations of the
embodiments described above with respect to the shapes, sizes, and
components of the systems and apparatuses, as well as alternatives
not described herein, without departing from the spirit and scope
of the present invention. Also, while the invention has been
described and shown herein with respect to several structures of
card multipacks and carriers thereof, the present invention is not
limited thereto. That is, in other embodiments, the stored value
cards may be contained in any other suitable carrier. For example,
in another embodiment of an automated system according to the
present invention, a large number of stored value cards may be
packaged in a carrier that is a box or other suitable container,
such as using a shuffle feeder. For example, the box or other
container may have a parent bar code that is associated with child
bar codes of the stored value cards, or the box may have a window
through which a parent bar code of one of the stored value cards
may be associated with child bar codes of other ones of the stored
value cards, and which may be verified using the automated system
according to an embodiment of the present invention. Further, the
number of stored value cards in the multipack is not limited by the
present invention. Further, in other embodiments of the present
invention, data acquisition or capturing is not limited to bar
codes or cameras, but, rather, may be performed by any other
suitable device, such as via magnetic stripes and magnetic stripe
readers. Similarly, in other embodiments of the present invention,
the bar codes of one or both of the stored value cards or the
carriers may be substituted with magnetic stripes or any other
suitable readable data device.
[0112] The preceding description has been presented with reference
to some exemplary embodiments of the invention. Persons skilled in
the art and technology to which this invention pertains will
appreciate that alterations and changes in the described structures
and methods of assembly and operation can be practiced without
meaningfully departing from the principles, spirit, and scope of
this invention.
* * * * *